Systems and methods for controlling strobe illumination

ABSTRACT

Various exemplary embodiments may provide systems and methods for strobe illumination of a workpiece. The systems may include an illumination source, an image acquisition device and a control system. The illumination source may emit visible, UV, or near-IR light as a transient flash to the workpiece, the transient flash occurring in response to a lamp trigger. The illumination source may emit the light at an illumination intensity that rises from a begin threshold to a peak and afterwards diminishes to an end threshold during a flash duration. The image acquisition device may capture the light associated with the workpiece for an exposure duration starting from an exposure trigger. The control system may control the illumination source and the image acquisition device to synchronize the lamp trigger so that the exposure duration ends during the flash duration, such that a remaining portion of the flash does not affect the image exposure.

BACKGROUND

This invention relates to systems and methods that select light source channels and control light intensity and direction for precision machine vision inspection using a transient light source.

Methods for operating a machine vision inspection system with a camera and a stage that are movable relative to one another to focus on and inspect selected features of a workpiece on the stage are generally known. Precision machine vision inspection systems may be used to obtain precise dimensional measurements of inspected objects and to inspect various other object characteristics.

Such systems may include a computer, a camera and/or optical system and a precision stage that may be movable in multiple directions to allow the camera to scan the features of a workpiece that is being inspected. One exemplary prior art system, of a type that may be characterized as a general-purpose “off-line” precision vision system, is the commercially available Quick Vision™ series of vision inspection machines and QVPak® software available from Mitutoyo America Corporation (MAC), located in Aurora, Illinois.

Such general-purpose “off-line” precision vision systems often include a programmable illumination system and a lens turret with lenses of various magnifications, for example, to increase versatility of the image systems and provide the ability to rapidly change configuration and imaging parameters for the vision systems to perform a wide variety of inspection tasks. There is a common need to inspect various types of objects or inspection workpieces, or various aspects of a single workpiece, using various combinations of magnifications and the programmable illumination settings.

General purpose precision machine vision inspection systems, such as the Quick Vision™ system, are also generally programmable and operable to provide automated video inspection. Such systems may include features and tools that simplify the programming and operation of such systems, such that operation and programming may be performed reliably by “non-expert” operators. For example, U.S. Pat. No. 6,542,180, which is incorporated herein by reference in its entirety, teaches a vision system that uses automated video inspection. The system performs operations to adjust the lighting used to illuminate a workpiece feature based on a plurality of selected regions of a feature image.

Imaging systems are widely used to inspect workpieces being transported through a manufacturing process. Equipment such as machine vision inspection systems often capture images of the workpieces using a camera, for example, and process captured images to verify various workpiece dimensions by identifying edges of relevant features in the images.

SUMMARY

The precise location and repeatability of where an edge is detected within an image depends on the lighting of the workpiece during image capture. Edge artifacts or edge-shifting may be created by lighting-specific shadows cast due to sub-optimal direction of the illumination of the workpiece. Over- or under-exposure may reduce the ability to accurately detect an edge, and decrease measurement repeatability. To increase productivity, workpieces may be kept in motion, even during image capture. This places an additional burden on illumination systems to minimize blurring caused by the motion. Such factors frequently limit the accuracy with which the edge of a feature may be located within an image and/or the velocity that may be tolerated during image capture. Thus, improvements in workpiece illumination control technology would be very desirable.

Various exemplary embodiments provide systems and methods for strobe illumination for imaging a workpiece. Exemplary systems may include an illumination source, an image acquisition device and a control system. The illumination source may emit light of one or more visible or invisible wavelengths of radiation that are suitable for imaging the workpiece, as a transient flash or pulse to the workpiece. The transient flash or pulse may occur in response to a lamp trigger. The illumination source may emit the light at an illumination intensity that rises from a begin threshold to a peak and afterwards diminishes to an end threshold during a flash duration. The image acquisition device may capture the light associated with the workpiece for an exposure duration started in response to an exposure trigger. The control system may control the illumination source and the image acquisition device to provide a desired overlap between the exposure duration and the flash duration. The beginning of the exposure duration may precede the lamp trigger by a lamp lag period. The lamp trigger may be set to synchronize or adjust a timing relationship between an end of the exposure duration and the illumination intensity profile of the flash.

In various exemplary embodiments, exposure triggers may correspond to predetermined positions of the workpiece relative to a coordinate space used by the machine vision inspection system.

In various exemplary embodiments, such a system may further include a spatial light modulator (SLM) that forms an array to control and/or distribute the light from one or more illumination sources. The array may include elements that selectively either block, partially transmit, or transmit the light toward respective lighting channels, such as respective optical fiber bundles. Each respective lighting channel may direct the light along a path to project commanded illumination from a respective position and/or angle of incidence relative to the workpiece.

BRIEF DESCRIPTION OF THE DRAWINGS

Various details are described below with reference to the following figures, wherein:

FIG. 1 shows a diagram of an exemplary general purpose machine vision inspection system;

FIG. 2 shows a block diagram in greater detail of a control system, a vision components system and a light source system of the exemplary machine vision inspection system;

FIG. 3 shows a block diagram in greater detail of the light source system and a lighting control interface;

FIG. 4 shows an exemplary graphical user interface of a control for a spatial light modulator;

FIG. 5 shows a schematic layout diagram of exemplary lighting system including a spatial light modulator;

FIG. 6 shows a bar-chart of exemplary relative grayscale intensities obtained when imaging various materials at different magnifications;

FIG. 7 shows a timing diagram of exemplary camera and flash triggers associated with strobe illumination and exposure control;

FIG. 8 shows a block diagram of an exemplary controller signals associated with a light generator and a vision measuring machine;

FIG. 9 shows a schematic layout diagram of exemplary light channels, including a structured light channel and a spatial light modulator;

FIG. 10 shows a plot illustrating exemplary generic relationships between a power setting and corresponding strobe duration times; and

FIG. 11 is a flowchart illustrating an exemplary method of using a strobe light source and a spatial light modulator to provide illumination levels for one or more light sources.

DETAILED DESCRIPTION OF EMBODIMENTS

The following detailed description refers to multi-channel strobe illumination for magnified image acquisition. The strobe illumination source may refer to a Xenon flashlamp, for example. However, the principles described herein may be equally applied to any known or later-developed transient illumination sources, beyond the examples specifically discussed herein.

Exemplary systems and methods for machine vision inspection, as provided herein, may be used in conjunction with systems and methods disclosed in U.S. patent application Ser. No. 10/719,210 (Attorney Docket 116523) filed on Nov. 24, 2003 directed to automatic focusing, and/or U.S. patent application Ser. No. 10/901,355 (Attorney Docket 119793) filed on Jul. 29, 2004 directed to strobe illumination, and/or U.S. patent application Ser. No. 10/435,625 filed on May 7, 2003 directed to improved machine vision inspection throughput, each of which is incorporated herein by reference in its entirety.

Various methods and GUIs usable for determining an optimum light setting to be used with rapid auto focus systems that determine an estimated best focus position and associated light adjusting systems are disclosed in U.S. Pat. Nos. 6,542,180 and 6,239,554, each incorporated herein by reference in its entirety. In addition, techniques for measuring surface contours are disclosed in U.S. Pat. No. 6,690,474, also incorporated herein by reference in its entirety.

FIG. 1 is a block diagram of an exemplary embodiment of a general purpose programmable machine vision inspection system 10 usable according to this invention. The machine vision inspection system 10 may include a vision measuring machine 200 that may be operably arranged to exchange data and control signals with a control system portion 120.

The control system portion 120 may be firther operably arranged to exchange data and control signals with at least one of a monitor 136 a, a printer 136 b, a joystick 138 a, a keyboard 138 b, and a mouse 138 c. The vision measuring machine 200 may include a moveable workpiece stage 210 and an optical imaging system 205, which may include a zoom lens or a number of interchangeable lenses. The zoom lens or interchangeable lenses may generally provide various magnifications for images produced by the optical imaging system 205.

The joystick 138 a maybe used to control the movement of the movable workpiece stage 210 in both X- and Y-axes horizontal directions, which may be generally parallel to the focal planes and perpendicular to the Z-axis movement direction of the optical imaging system 34. Frequently, Z-axis movement may be controlled by a rotary deflection component of a handle or knob of the joystick 138 a. The joystick 138 a may be provided in a form other than that shown, such as any visual representation or widget on the monitor 136 a that may be intended to function as a “virtual motion control device” of the machine vision inspection system 10 and is controllable through any computer input device, such as the mouse 138 c or other analogous devices.

FIG. 2 shows a detailed block diagram of a machine vision inspection system 10′, which is an exemplary embodiment of the machine vision inspection system 10, that includes the control system portion 120, the vision measuring machine 200 and, in addition, includes a controllable light generation system 300. The control system portion 120 may be arranged to exchange data and control signals with both the vision measuring machine 200 and the light generation system 300.

The control system portion 120 may include a controller 125 that may be in communication with, or connected to, an input/output interface 130, a memory 140, a workpiece program generator and executor 170, a computer-aided design (CAD) file feature extractor 180 and a power supply portion 190. The control system portion 120 may also be arranged to exchange data and control signals with display devices 136 and input devices 138, for example, through the input/output interface 130.

The input/output interface 130 may comprise an imaging control interface 131, a motion control interface 132, a lighting control interface 133, and a lens control interface 134. The motion control interface 132 may include a position portion 132 a and a speed and acceleration portion 132 b. The lighting control interface 133 may include lighting channel exposure and control portion 135.

The various elements of the control system portion 120 may generally encompass hard-wired circuits, software circuits, subroutines, objects, operations, application programming interfaces, managers, applications, or any other known or later-developed hardware or software structure. The display devices 136 may include, for example, the monitor 136 a and the printer 136 b (FIG. 1). The input devices 138 may include, for example, the joystick 138 a, the keyboard 138 b and the mouse 138 c (FIG. 1). In general, the various elements of the control system portion 120, may be operably connected to each other and to external devices by any suitable known or later-developed power and/or signal busses, wireless communication signals, and/or application programming interfaces, or the like. Such interconnections are generally indicated by various interconnection lines 195, throughout the control system portion 120, in an arrangement of interconnections that is exemplary only, and not limiting.

The light generation system 300 may include one or more light generator 310 and a spatial light modulator (SLM) 350 to control the distribution of light from the light generator 310, to a plurality of light channels, as described further below. The light generator 310 and the SLM 350 may be arranged to exchange data and control signals with the light channel exposure and control portion 135, for example, by respective power and signal lines 311, 351. At least one of the lamps (not shown) of the light generator 310 maybe used in a strobe illumination mode of operation to provide a combination of a very fast light generator response time (in the As or ns range) and suitable optical power levels. In various exemplary embodiments, the light generator 310 may include a high intensity Xenon (Xe) flashlamp. However, in general, any light generator that emits a wavelength within a sensing range of the camera 260 may be used. Various features of the light generation system 300 are described further below.

The vision measuring machine 200 may include an optical assembly 205, light sources, including stage light source 220, coaxial light source 230, and programmable ring light (PRL) source 240. The workpiece stage 210 may include a central transparent portion 212 through which light from the stage light source 220 passes. The stage 210 may be controllably movable along X- and Y-axes that lie in a plane substantially parallel to the surface of the stage 210 where a workpiece or target 20 may be positioned.

The stage light source 220 may receive light through a light cable 221 from a respective channel of the SLM 350 to transmit light 222 through the transparent portion 212. The components that provide the light 222 may be regarded as a first light channel of the machine vision inspection system 10′. The coaxial light source 230 may receive light through a light cable 231 from a respective channel of the SLM 350 to transmit light 232 to a beamsplitter that provides a coaxial mirror 233 that directs the transmitted light 232 through the objective lens 250. The components that provide the light 232 may be regarded as a second light channel of the machine vision inspection system 10′. The programmable ring light (PRL) source 240 may form an annular ring above and around the workpiece 20 to transmit light 242 to the workpiece 20 at controllable angles. An exemplary configuration for the PRL source 240 may include four ring-light sources 240 a through 240 d, arranged in respective quadrants around the ring-light. The four sources 240 a through 240 d may receive light through respective light cables 241 a through 241 d from respective channels of the SLM. 350. The various light cables may comprise optical fiber bundles, or the like. The PRL source 240 may be formed as a combination of individually controllable sources. The components that provide respective portions of the light 242 may be regarded as four additional light channels of the machine vision inspection system 10′.

The workpiece 20 may be disposed on the stage 210 at a known or learned position. By detecting macroscopic positions of the stage 210 and/or the workpiece 20, the control system portion 120 may accurately determine where to capture workpiece images to perform inspection of various workpiece features.

The memory 140 may comprise an image file memory portion 141, a workpiece program memory portion 142, and a video tool portion 143. The video tool portion 143 may comprise a region of interest generator 143 x, and various respective video tools 143 a through 143 m, which may include respective GUI interfaces, image processing operations, and the like, which assist a user in performing and/or programming various inspection operations. The region of interest generator 143 x provides operations that may assist the user in defining desired regions of interest to be analyzed or operated upon be the various video tools 143 a-143 m, as described in the '180 patent, for example.

The memory 140 may store data and/or “tools” usable to operate the machine vision inspection system 10 to capture or acquire an image of the workpiece 20 with desired image characteristics. The memory 140 may further store data and/or video tools usable to operate the machine vision inspection system 10 to perform various inspection and measurement operations on the acquired images, either manually or automatically, and to output the results, for example, through the input/output interface 130 through data and/or control busses and/or the controller 125. The memory 140 may also contain data defining a GUI operable through the input/output interface 130 by way of data and/or control busses and/or the controller 125.

The optical assembly 205 may include, for example, a camera or image acquisition device 260, an interchangeable objective lens 250, a turret lens assembly 280, and the coaxial light source 230. The objective lens 250 and the camera 260 may be aligned along a camera axis. The optical assembly 205 may be controllably movable along the Z-axis that is generally orthogonal to the X- and Y-axes, for example, by using a controllable motor 294. Each of the X-, Y- and Z-axes of the machine vision inspection system 10 may be instrumented with respective X-, Y- and Z-axis position encoders (not shown) that provide spatial position information to the control system portion 120, for example, over suitable signal and/or control lines (not shown). The camera 260 may include a charge-couple diode (CCD) array, or a CMOS array, or any other suitable detector array, to provide an image based on the light received from the workpiece 20.

The turret lens assembly 280 may include two or more respective lenses 286, 288 that may be rotated around a rotation axis 284 to be respectively positioned in the optical path between the camera 260 and the objective lens 250 to provide a respective image magnification in combination with the objection lens 250. The control system portion 120 may rotate the turret lens assembly 280 to provide a desired image magnification. The input/output interface 130 may exchange data and control signals with the camera 260, the turret lens assembly 280 and the motor 294, for example, by power and signal lines or busses 262, 281, 296. Respective signal and/or control lines (not shown) of the respective X-, Y- and Z-axes position encoders (not shown) may also be in communication with the input/output interface 130. In addition to carrying image data, the signal line 262 may carry various signals from the controller 125 that set an image acquisition pixel range for the camera 260, initiate an image acquisition camera operation sequence, and/or similar operations.

The optical assembly 205 of the machine vision inspection system 10 may include, in addition to the previously discussed components, other lenses, and/or other optical elements, such as apertures, beam-splitters and other analogous devices, such as may be needed for providing desirable machine vision inspection system features.

The workpiece 20 to be imaged and inspected using the machine vision inspection system 10 may be placed on the stage 210. One or more of the light sources 220, 230, 240 may emit the respective light 222, 232, 242, that may illuminate the workpiece 20. Light may be reflected from or transmitted through the workpiece 20 as workpiece light 255, which may pass through the interchangeable objective lens 250 and one of the lenses 286, 288 of the turret lens assembly 280 to be received by the camera 260. The image of the workpiece 20, captured by the camera 260, may be output, for example, through the signal line 262 to the control system portion 120.

A distance between the stage 210 and the optical assembly 205 may be adjusted to change the focus of the image of the workpiece 20 captured by the camera 260. For example, the optical assembly 205 may be movable in the vertical (Z-axis) direction perpendicular to the stage 32, for example, using the controllable motor 294 that may drive an actuator, a connecting cable, or other analogous devices, to move the optical assembly 205 along the Z-axis. The term Z-axis, as used herein, refers to the axis for focusing the image obtained by the optical assembly 205. The controllable motor 294, when used, may be in communication with the control system portion 120, for example, through the signal line 296.

The control system portion 120 may be usable to determine image acquisition settings or parameters and/or acquire an image of the workpiece 20 with desired image characteristics in a region of interest that includes a workpiece feature to be inspected by workpiece program instructions. Such workpiece imaging instructions may be encoded by the workpiece part programming generator and executor 170 and transmitted to other components through data and/or control busses and/or application programming interfaces 195. The display devices 136 and input devices 138 may be used to view, create and/or modify part programs, to view the images captured by the camera 260, and/or to view and/or modify various GUI features for monitoring and/or controlling the machine vision inspection system 10′. The physical movements may be controlled by the motion control interface 132.

To achieve control of the physical movements of the camera 260, the motion control interface 132 may receive position information from the X-, Y- and Z-axis position encoders and may transmit position altering control signals via data and/or control busses and/or application programming interfaces 195. In general, such. instructions may cause the machine vision inspection system 10′ to manipulate the stage 210 and/or the camera 260 such that a particular portion of the workpiece 20 may be within the field of view of the camera 260 and may provide a desired magnification, a desired focus state and an appropriate illumination. This process may be repeated for each of multiple images in a set of images that are to be captured for inspecting the workpiece 20.

FIG. 3 shows an exemplary block diagram of details of the lighting control interface 133 including the light channel and exposure control portion 135, and the light generation system 300. The light channel and exposure control portion 135 may include a timing and synchronization portion 135 a, an SLM control portion 135 b and a light generator control portion 135 c. The SLM control portion 135 b may be connected to the SLM 350, for example, through a signal line or buss 351. The light generator control portion 135 c may be connected to the light generator 310, for example, through a power and/or signal line or buss 311.

The light generator 310 may emit light 314 to illuminate an illumination area 315 on the SLM 350. The SLM 350 may generally transmit, partially transmit, or block light. The SLM 350 may include a plurality of respective controllable apertures within the illumination area 315. The respective apertures may generally provide illumination control for the respective light channels of the machine vision inspection system by transmitting, partially transmitting, or blocking the light 314 to each of the respective light channels. In the example shown in FIG. 3, the apertures include a stage light channel aperture 321, a coaxial light channel aperture 331, and PRL light channel apertures 341 a, 341 b, 341 c, 341 d. The respective apertures 321, 331, 341 a-341 d may individually control the amount of light 314 transmitted to the respective light cables 221, 231, 241 a-241 d (FIG. 2) to be output through the respective light sources 220, 230, 240 a-240 d.

The SLM 350 may include an arrangement of shutters that provide the respective apertures. The shutters may be of any now-known or later-developed type that can provide controllable light transmitting and light blocking fimctions in a desired pattern. In various embodiments, it may be advantageous if the shutter may also be used to partially-transmit light. For example, such that the SLM may be used to selectively transmit, attenuate and/or block light from the light generator 310. One example of such an SLM may be a micro-display graphics array from CRL-Opto in Dunfermline, Scotland, United Kingdom, which includes an LCD pixel array that may generally be controlled by conventional video signals, if desired, and may be used to display an electronically generated 8-bit gray-scale pattern that may transmit, partially-transmit, or block the light 314 through any given pixel of the pattern, depending on its gray-scale value. In such a case, the various respective apertures may be implemented as features of the pattern, and the pattern may be controlled at conventional video rates. Alternatively, a custom LCD including a custom pattern of desired apertures may be used in various embodiments. It should be appreciated that the SLM 350 allows one light generator 310 to provide independently controllable lighting to a plurality of light channels, while also allowing the light from a plurality of light channels to be perfectly synchronized, for example as one light generator 310 is strobed during an image acquisition. The use of one light generator 310 also allows reduced cost and reduced size, relative to the use of an individual light generator for each light channel, for example.

Alternatively, the SLM 350 may include an arrangement of any now-known or later-developed type of controllable reflective shutters that can provide controllable light deflection in a desired pattern. In such a case, the light generator 310 may be arranged such that the light 314 will not reach the various light channels unless the controllable reflective shutters or pixels “transmit” the light by reflecting and/or deflecting light at a specific angle toward the various light channels. For example, in contrast to FIG. 3, the reflective SLM may be nominally oriented along a plane at 45 degrees relative to the light 314, and the reflective array elements may be aligned along that plane to transmit the light 314 toward the various respective light channels by reflecting and/or deflecting it at a right angle to reach the various respective light channels. To effectively “block” the light 314 from reaching the various light channels, the reflective array elements or pixels may be disabled from reflecting the light 314 at right angles, either by altering their individual angles, of by blocking their individual reflective light paths, for example using individually controllable LCD blocking elements. Examples of controllable reflective shutter arrays that may be used include liquid crystal on silicon (LCOS) micro-display products, for example, from CRL Opto, Dunfermline, Scotland, and digital light projector (DLP) micro-mirror products, for example, from Texas Instruments DLP Products, Plano, Tex. In such a case, the various respective apertures may be implemented as features of a reflective pattern, and the pattern may be controlled at conventional video rates. Although the micro-mirror type of devices may not provide partially-transmitting pixels, it will be appreciated that a light channel aperture implemented using a micro-mirror device may alternatively attenuate the light transmitted to a particular light channel by effective reducing the its aperture size, as needed. For example, the aperture diameter may be reduced by altering the configuration of the pixels that form the aperture.

As previously outlined, it may be advantageous if at least one of the lamps of the light generator 310 may be used in a strobe illumination mode of operation to provide a combination of a very fast light generator response time (in the ls or ns range) at suitable optical power levels. Such illumination is particularly advantageous for allowing imaging of workpieces while continuing to move the stage 210 (FIG. 2), which increases the throughput of the machine vision system 10′. One example of a light generator 310 may include one or more high intensity light emitting diodes (LEDs), such as one of the LEDs in the Luxeon™ product line, available from Lumileds Lighting, LLC, of San José, Calif., which may be used for both continuous wave (CW) and strobe illumination as described in U.S. patent application Ser. No. 10/719,210. In various exemplary embodiments, a CW light source may include a high intensity discharge (HID) metal halide lamp and/or a quartz halogen lamp.

In various exemplary embodiments, the strobe light generator may include a high intensity Xenon (Xe) flashlamp, such as model CX-1500 Xe flashlamp of the CX-Strobeg series from PerkinElmer® Optoelectronics of Frémont, Calif. The CX-1500 Xe flashlamp may illuminate across an electromagnetic spectrum for wavelengths between 250 nm and more than 1100 nm. In various embodiments, it may be desirable to filter the light from the flashlamp, to reduce heating and/or chromatic aberrations. For example, the filter may pass the visible wavelength range between 390 nm (violet) and 750 nm (red) to the light channels. However, in various embodiments, other wavelengths ranges may be desired. The CX-1500 Xe flashlamp may cycle at a repeat rate of between 16 Hz and 35 Hz, with a pulse duration of between 8 μs and 10 μs. The CX-1500 Xe flashlamp may produce a radiometric output of 256 mJ and a photometric light output of 205 lumen-sec at 600 VDC that may be directed into a 0.9″ (23 mm) diameter fiber optic guide.

It should be appreciated that a general purpose machine vision systems may image a wide variety of workpieces, some of which may have surfaces with low reflectivity. Furthermore, magnified images may be desired. Furthermore, fast exposures, enabling imaging of moving workpieces may be desired. All of these factors tend to reduce the amount of light accumulated during an image exposure, as discussed further below. Thus, a very high intensity flashlamp may be advantageous for providing a very versatile machine vision inspection system.

The timing and synchronization portion 135 a may provide operations that send and receive control signals that synchronize the SLM 350, the light generator 310, the camera 260 and positioning of the machine vision inspection system 10′. The SLM control portion 135 b may provide control for the various light channels by controlling the on-off timing, contrast, and aperture pattern, if applicable, of the SLM 350. The light generator control portion 135 c may provide control for the power levels, the trigger signals, and on-off timing (if applicable) of the one or more lamps or LED's, or the like, of the light generator 310. The light generator control portion 135 c may also provide for light path control for auxiliary light sources (if applicable), as outlined further below.

FIG. 4 shows an exemplary SLM setup and control GUI 400 including an SLM image field 410 and a control window 420. The SLM image field 410 shows one exemplary aperture pattern including a stage light channel aperture representation 431, a coaxial light channel aperture representation 421, and PRL light channel aperture representations 441 a, 441 b, 441 c, 441 d. The respective aperture representations may correspond to the apertures 321, 331, 341 a-341 d of the SLM 350, for example. The control window 420 includes a stage light channel aperture control 531, a coaxial light channel aperture control 521, and PRL light channel aperture controls 541 a, 541 b, 541 c, 541 d, which control the similarly numbered aperture representations, and a set of corresponding control signals that may be implemented to control the SLM 350. For example, when the SLM 350 is an LCD pixel array, the pixel array may be controlled such that the gray-scale values that control the pixel array correspond to the gray-scale values of the pixels shown in the SLM image field 410.

For the example shown in FIG. 4, the double cross-hatched background represents a light-blocking region of the SLM 350. The stage light channel aperture representation 431 shows a similar double cross-hatching to represent a significantly light-blocking setting of the corresponding control 531. The coaxial light channel aperture representation 421 shows an unfilled area to represent a significantly light-transmitting setting of the corresponding control 521. The PRL light channel aperture representations 441 a, 441 b, 441 c, 441 d, show single cross-hatching to represent a partially light-transmitting setting of the corresponding controls 541 a, 541 b, 541 c, 541 d. The layout of the aperture representations 421, 431, and 441 a-441 d in the SLM image field 410 may correspond directly to a physical layout of the apertures 321, 331, and 341 a-341 d of the SLM 350, and to a physical layout of the input ends of the light cables 221, 231, and 241 a-241 d (FIG. 2), which may be held in a fixture proximate to the SLM 350, such that they are properly aligned to receive transmitted light from the corresponding apertures. The particular layout shown in FIG. 4 is exemplary and is not limiting. Other configurations are possible and contemplated. It will be appreciated that the various aspects of aperture control described above with reference to FIG. 4, may also generally be provided under manual, semi-automatic, or automatic control as finctions of the SLM control 135 b. Accordingly, these and other manual, semi-automatic, or automatic control measures over the apertures 321, 331, and 341 a-341 d of the SLM 350 may be implemented to support various learn mode and/or run mode operations of the machine vision inspection system 10′.

The control window 420 may include panels with the “slider” controls outlined above, along with corresponding numerical settings, along with other slider controls, numerical displays and radio buttons to adjust and display selected parameters which may control the light intensities of the various lighting channels and their representations in the SLM image field 410. The PRL panel may include a “gang” PRL radio button 425 that indicates whether the PRL sources 240 a through 240 d are ganged together, i.e., adjusted to the same setting, rather than separately controlled.

The slider control scales may denote the range (from none to full) of the intensity to be transmitted by the corresponding aperture. The slider control pointer and the numerical display may indicate the selected value to which the respective light source intensity may have been set. The numerical display may denote a digital quantity across a binary integer grayscale range of 2⁸ from full illumination at 255 to no illumination at 0. In the example illustrated, the stage control panel 531 shows, for example, a low-level value of 71, the coaxial control panel 521 shows, for example, a high-level value of 234, while all the PRL control panels 541 a-d show, for example, a mid-level value of 130. The PRL radio button 425 shows, for example, that the PRL sources are ganged together in this example.

A background radio button 426 may indicate a selection of the display background, being either white or black, shown in the example as being black (double cross-hatched.) In a set-up mode of operation, the respective slider controls of “Shift” scales 427V and 427H may be used to adjust the position of the aperture pattern shown in the SLM image field 410 over a limited range along the vertical (V) and horizontal (H) directions, respectively. The actual location of the aperture pattern of the SLM 350 may be controlled in a corresponding manner. The alignment of the actual aperture pattern of the SLM 350 relative to the physical layout of the input ends of the light cables 221, 231, and 241 a-241 d (FIG. 2), which may be held in a fixture proximate to the SLM 350, may be monitored by direct observation, or by monitoring a light transmission signal through the various light channels or the like, until the various apertures have been properly aligned to the various light cable using the “Shift” controls. Then the corresponding “calibration” settings may be stored in the SLM control 135 b, for use during ongoing operations of the machine vision inspection system 10′.

FIG. 5 shows an exemplary schematic layout diagram of the light generation system 300, including light generator(s) 310 and a spatial light modulator 350. A collimator lens 312 may receive light 314 from one of a CW lamp 316, such as an HID lamp, or a Xe strobe 317. Both may have substantially elliptical mirrors. A hinged mirror 313 may pivot to enable either the HID lamp 316 or the strobe 317 to transmit light through the collimator lens 312. In a first position 316 b, the light from HID lamp 316 is blocked by the mirror 313, and the Xe strobe 317 may shine directly into the collimator lens 312. In a second position 317 b, the light from Xe strobe 317 is blocked by the mirror 313, and the light from HID lamp 316 may be reflected into the collimator lens 312.

In either case, a light 314 may pass through the collimator lens 312, and be directed as collimated, or approximately collimated, light toward the SLM 350. In the example shown in FIG. 5, the light 314 may pass through an aperture 317, which may define the illumination area 315 (FIG. 3), and may then pass through a filter 318 to block wavelengths that may contribute deleterious effects, such as undesirable heating, or image blur, or the like. For example, in some applications, wavelengths in the ultraviolet portion of the electromagnetic spectrum may focus differently than a dominant imaging wavelength and degrade images. The light may then pass, for example, through the previously discussed respective apertures of the SLM 350 and into the respective optical cables of the optical cable arrangement 319 that are aligned with the respective apertures, to be transmitted to the respective positions of the illumination sources 220, 230, and 240, for example. The input ends of the optical cables of the optical cable arrangement 319 may be inserted into an alignment and mounting plate (not shown) that has a plurality of holes that receive the ends of the optical cables and hold them in an alignment that matches the aperture pattern of the SLM 350. The mounting plate may be mounted proximate to, or flush to, the SLM 350, and may also act as an optical baffle or barrier between the outputs of the various apertures and the optical cable ends, to reduce stray light “cross talk” between the light channels. An alternative configuration is shown in FIG. 9, described below.

FIG. 6 shows an exemplary bar chart 600 for the relative average grayscale intensity observed using a typical camera and constant illumination, for sundry workpiece surfaces at specific magnifications. Several materials, each at 1×, 2× and 6× magnification are listed along the abscissa 610, including floppy disk, brown connector, textured metal, green printed circuit board (PCB), integrated circuit (IC) lead, white connector, metal mirror and glass mirror. The 8-bit relative average grayscale intensity along the ordinate 620 ranges from 0 through 255, where zero is no intensity and 255 represents camera saturation or overexposure.

As may be observed from the bar chart, increases in magnification reduce the amount of gathered light and the photographic exposure, and generally would demand greater quantities of light to provide sufficient photographic exposure. Also, darker materials, such as the floppy disk may require far greater quantities of light than brighter materials, such as the white connector, or specularly reflective materials, such as the mirrors. This difference in the amount of exposure light received for various materials and magnification demonstrates that the light levels that may be required for imaging and inspection of various magnified surfaces in a general purpose machine vision inspection system may vary widely. In fact, if the saturation values shown for the low-magnification imaging of various materials are to be avoided, and if the low illumination values shown for the higher-magnification imaging of various materials are to be brought up to acceptable imaging levels, the illumination intensity may be required to be adjustable over a range of many orders of magnitude. Thus, there is a need for an illumination system that provides an extraordinarily wide dynamic range and precise control of available illumination.

To increase throughput, imaging the workpiece 20 disposed on the stage 210 may be performed while the stage 210 remains in motion. Under selected conditions of image magnification and stage speed, a strobe light flash of high intensity and short duration may be required to sufficiently illuminate the workpiece 20 in a short enough exposure time to avoid image blur during workpiece motion. To achieve a desirable illumination dynamic range with short illumination and/or exposure durations, an extremely bright strobe lamp, such as a Xe lamp, may be advantageous. For many types of lamps (which may also include LED's, or lasers, or the like, as the term “lamp” is used herein), after being triggered the strobe flash “profile” may temporally change in light intensity beginning with a gradual initial rise, followed by a rapid increase, a leveling off, a rapid reduction and a more gradual decay. Providing a reliable and consistent illumination exposure over a wide dynamic range using such a flash profile would be desirable.

FIG. 7 shows an exemplary timeline chart 700 for trigger control of a strobe pulse and a camera integration period used for imaging. The exposure level for an image may be determined by the transient light level integrated by the camera over the exposure duration. The exposure duration may generally be limited by the strobe duration, or, when CW illumination or “long” illumination pulses are used, by the camera integration period. However, it is one goal of precision machine vision inspection systems to provide highly consistent precision metrology images that do not vary from workpiece to workpiece, such that edge measurements and the like, which form the basis for precision inspection, do vary from workpiece to workpiece unless the workpieces truly vary. Thus, in order to mitigate the changes in effective duration of the decay portion from one strobe flash to another, resulting in unacceptable variation in the total image exposure illumination, it may be desirable to truncate the decay portion of the flash by ending the camera integration period at a consistent time within the flash period. Furthermore, it should be appreciated that with a Xe lamp, for example, the ability to vary the flash duration may be limited, and the flash duration may be inherently less that a typical minimum camera integration period. Therefore, methods to reduce the effective exposure illumination provided by a strobe flash, by orders of magnitude, with consistent control, may be desirable.

The chart 700 includes, for example, five timelines. The first timeline 710 represents an image acquisition trigger signal 715 beginning at a position trigger time T_(pta) based on positional X-, Y- and Z-axis coordinates of the stage 210 (FIG. 2), which may correspond to a workpiece feature being positioned in the field of view of the camera 260.

The second timeline 720 represents a camera integration duration 725, that may have a programmable duration (T_(ei)-T_(si)) as short as tens of microseconds, and as long as several milliseconds. The controlled duration may be controlled based on a high-speed clock, such that it is relatively consistent. The camera integration duration 725 may start at integration begin time T_(si) and end at integration end time T_(ei). In some implementations, the integration begin time T_(si) may occur a discrete latency period (T_(si)-T_(pta)) after the position trigger time T_(pta) has been used to initiate a camera integration period. However, the latency period may be relatively consistent.

The third timeline 730 represents the flash initiation signal 735 beginning at a pulse trigger time T_(pt) to initiate the strobe flash. In some implementations, the pulse trigger time T_(pt) may be based by the same high-speed clock that is used to determine the camera integration duration 725. Therefore, a pulse trigger delay period (T_(pt)-T_(si)) may be programmable, based on the high-speed clock, and relatively consistent. The beginning of the pulse trigger time T_(pt) may initiate the strobe pulse flash intensity profile indicated by the fourth timeline 740. The flash intensity may exhibit a transient profile, described further below, that rises to a peak 745 before diminishing.

The fifth timeline 750 represents an exposure-related coordinate position latch signal 755 beginning at latch time T_(txyz) that may coincide with an effective or nominal exposure time. The X-, Y- and Z- coordinates for the stage 210 or the workpiece 20 at the latch time T_(txyz) may be associated with the acquired image and may be stored in memory 140. Descriptions of the timeline events, listed in order of occurrence during an image acquisition cycle, are summarized in Table 1 below. TABLE 1 Event No. Time Label trigger image acquisition 715 position trigger acquisition T_(pta) begin camera image 725 start integration T_(si) integration (T_(si) → T_(ei)) strobe flash initiation 735 pulse trigger T_(pt) flash pulse start start pulse T_(sp) flash peak intensity 745 position latch signal 755 xyz coordinate assigned to T_(txyz) image end camera image integration end T_(ei) integration (T_(si) → T_(ei)) flash pulse end end pulse T_(ep)

The strobe pulse flash intensity profile begins at the pulse trigger T_(pt) with an initial gradual rise until effective start of the flash at time T_(sp). After a rapid rise to a peak value 745, the flash may then diminish rapidly, to an effective end point of the flash at a time T_(ep), and then continue to decay, providing little additional illumination energy, as shown in FIG. 7. For a particular implementation and an particular lamp, a latency period between the pulse trigger time T_(pt) and the effective pulse start time T_(sp) may be relatively consistent. Furthermore, for a given time period (T_(ep)-T_(sp)), the intensity profile and the illumination energy provided at a particular operating voltage for a particular lamp may be relatively consistent.

As previously indicated, with a Xe lamp, for example, the ability to vary the flash duration (or profile) may be limited, and the flash duration may be inherently less than a typical minimum camera integration period. Therefore, to reduce the effective exposure illumination provided by a strobe flash, by orders of magnitude, with consistent control, it may be desirable that the camera exposure end at a predictable and consistent time before the effective end time T_(ep) of the flash. As previously indicated, the pulse trigger delay period (T_(pt)-T_(si)) may be programmable, based on the high-speed clock, and relatively consistent. Similarly, the programmable camera integration duration (T_(ei)-T_(si)) may be programmable, based on the same high-speed clock, and relatively consistent. Furthermore, the latency period between the pulse trigger time T_(pt) and the effective pulse start time T_(sp) may be relatively consistent. Therefore, for a given flash time period (T_(ep)-T_(sp)) and associated profile, the effective exposure illumination may be controlled by selecting and/or programming the programmable camera integration duration (T_(ei)-T_(si)), and the pulse trigger delay period (T_(pt)-T_(si)) such that camera integration end time T_(ei) ends at a predictable time during the flash profile, and truncates and determines the effective image exposure illumination. That is, to control the effective image illumination over a wide dynamic range, the start of the effective image exposure illumination may begin with the flash, a short time following the start of the camera integration period, and may end with the end of the camera integration period, during the strobe flash profile. Of course, all of the above latency times may calibrated or determined for particular machines, lamps, voltage levels, etc., by design and/or experiment, and the results calibrated or stored such that a combination of timing, operating voltages, and the like, that provide a desired or calibrated illumination level may be readily determined.

FIG. 8 shows an exemplary schematic block diagram including exemplary controller signals associated with portions of the control system portion 120, the vision measuring machine 200 and the light generation system 300, shown in FIGS. 2 and 3. The control system portion 120 includes the imaging control interface 131 that may comprise a frame-grabber, the motion control interface 132, and the SLM control portion 135 b (FIG. 3). The motion control interface 132 may comprise a motion controller. The light generation system 300 may include the light generator 310, the SLM 350 and an SLM interface portion 135 b′. The timing and synchronization portion 135 a may be located with, or packaged in, the light generation system 300, which may facilitate retrofit applications of the light generation system 300.

The light generation system 300 may operate in conjunction with the SLM control portion 135 b, the timing and synchronization portion 135 a (FIG. 3) and a video splitter 810. The timing and synchronization portion 135 a and the SLM control portion 135 b may be components of the light channel exposure and control portion 135 (FIG. 2). The vision measuring machine 200 (FIG. 2) includes the camera 260 and light sources 220, 230, 240 to illuminate the workpiece 20. The coaxial mirror 233 directs the light from the coaxial light source 230 toward the workpiece 20.

The camera 260 may receive signals from the imaging control interface 131, and may transmit image data via the imaging control interface 131 via a video input 820. The camera 260 may also receive and transmit signals between a serial communicator 830. A digital monitor 840 and/or an analog monitor 850 may display information related to the SLM 350 (for example, as one means to implement the SLM setup and control GUI 400, described with reference to FIG. 4). The SLM control portion 135 b may supply SLM video signals to the video splitter 810 and the digital monitor 840. The video splitter 810 may supply video signals to the timing and synchronization portion 135 a, and the SLM interface portion 135 b′, as well as with the analog monitor 850. For example, the video signal supplied to the SLM interface portion 135 b′ may be a conventional video signal, and the SLM interface portion 135 b′ may receive and decode the video signal into digital control signals suitable for operating an SLM 350 that may comprise an LCD pixel array, to produce a desired aperture configuration and operating state. Generally, such SLM interface decoders are commercially available from many vendors of LCD pixel array displays, such as the vendor of the LCD array previously described.

The timing and synchronization portion 135 a may receive a position trigger output signal (for example, see 715, FIG. 7) from the motion control interface 132 (conventional motion controllers may be programmed to provide such position triggers) and relay a related signal to the imaging control interface 131 (“OptoTRIG” in FIG. 8) to maintain the timing relationships described with reference to FIG. 7. The imaging control interface 131 may supply an exposure trigger signal to the camera 260 to initiate the start of a camera integration period (for example, see 725, FIG. 7) and supply a pulse trigger (for example, see 735, FIG. 7) to the light generator 310, which may provide light to the SLM 350 for distribution to the light sources 220, 230, 240. The pulse trigger signal may be delayed relative to the exposure trigger signal by a programmable amount, based on a high speed clock included in the imaging control interface 131. This programmable delay, in conjunction with the programmed integration period of the camera 260 (and, possibly, various consistent timing latencies) may be used to control the effective image exposure illumination, as previously described with reference to FIG. 7. The high speed clock and the programmable integration period and pulse trigger signal delay may be implemented in various commercially available frame grabbers.

The timing and synchronization portion 135 a may supply a position latch trigger signal (for example, see 755, FIG. 7) to the motion control interface 132, in order to latch the X-, Y- and Z- coordinates for the stage 210 or the workpiece 20 at a time that corresponds to the effective image exposure time. For example, the timing and synchronization portion 135 a may implement a latching time that best corresponds to the effective image exposure time based on the known pulse trigger signal time and the known camera integration period, which allows the timing of the effective image exposure period (for example, see T_(ei)-T_(sp), FIG. 7) to be known. For example, for short effective image exposure periods, it may be sufficient for the position latch timing to be set at the middle of the period (T_(ei)-T_(sp)). Or, for a more accurate effective image exposure time, the position latch time may be set at the intensity-weighted average time of the period (T_(ei)-T_(sp)), based on the known flash intensity profile, which may be determined experimentally, for example. The pulse trigger signal time that is used to determine the effective image exposure time may be determined internally to the timing and synchronization portion 135 a, based on a delay related to the signal supplied to the imaging control interface 131 (“OptoTRIG” in FIG. 8), or, optionally, the pulse trigger signal time that is used may be determined based on sending the pulse trigger signal in parallel to the synchronization portion 135 a, when it is sent to light generator 310.

Examples of selected components are described herein. The serial communicator 830 may represent an interface control tool. The control system portion 120 may include a personal computer backplane with the SLM control portion 135 b provided by a Matrox dual video interface (DVI) daughter board and the imaging control interface 131 including a Corona II frame-grabber, both available from Matrox Electronic Systems Ltd, St-Régis Dorval (Quebec), Canada. The vision measuring machine 200 may use Quick Vision™ controls for controlling the various light sources. The SLM interface portion 135 b′ and the SLM 350 may be provided by a micro-display graphics array and associated electronics from CRL-Opto in Dunfermline, Scotland, United Kingdom. The motion control interface 132 may include a motion controller, for example one of the DMC-XXXX series of motion control cards commercially available from Galil Motion Control, Rocklin, Calif., or a motion control card such as that supplied as part of the previously described Quick Vision™ systems.

FIG. 9 shows a schematic layout diagram of an alternate configuration of the light generation system 300′, including a light source channel that provides a structured light source 945. The light generation system 300′ is generally similar to the light generation system 300 described with reference FIG. 5, therefore, only significant differences will be described. In a first portion, the light 314 is provided, as previously described with reference to FIG.5.

The light 314 may be channeled, for example, through a fiber bundle light conduit 910 to then pass, as collimated light 314′, through the aperture 317, the filter 318 and the SLM 350, which are located in a second portion of the light generation system 300′. The second portion of the light generation system 300′ may include a hinged mirror 920, similar to the hinged mirror 313. In a first position 921 a, the light 314′ may shine directly into the previously described optical cable arrangement 319, to provide all of the previously described illumination functions.

Alternatively, the SLM 350 may be a controllable element that may include, or be configurable or programmable to form, a structured light pattern, in addition to the exemplary aperture patterns described above. For example, the structured light pattern may include a regular pattern of light (light transmitting) and dark (light blocking) stripes at a desired pitch, and may be formed using the previously described LCD pixel array. In such a case, the collimated light 314′ that passes through the SLM 350 will may provide a field of parallel stripes of light. In a second position 921 b, the hinged mirror may deflect the parallel stripes of light to pass through focusing and/or magnifying, and/or collimating lenses 930 before being emitted to provide a structured light source 945 that may be used to illuminate the workpiece 20 (FIG. 2). The structured light source 945 may be mounted at a fixed and/or known position to emit the parallel light stripes toward the workpiece 20 along an axis that is arranged at a known angle relative to the optical axis of the machine vision inspection system 10′. Thus, an image of the structured light pattern on the surface of the workpiece 20 may be used in conjunction with known structured light triangulation techniques to determine relative dimensions of the profile of the workpiece 20 along the Z-axis direction. Various related teachings regarding the use of LCD arrays and structured light techniques are included in U.S. Pat. No. 6,690,474, which is incorporated herein by reference in its entirety.

It should be appreciated that in embodiments where the SLM 350 may be implemented such that the various respective channel apertures may be partially transmitting, for example, when the previously described LCD pixel array is used, the SLM 350 may advantageously be used to increase the dynamic range of the effective image exposure illumination. That is, in addition to the dynamic range control provided by the previously described measures of controlling the camera integration period and the strobe flash timing, gray-level control of an LCD pixel array, or a custom LCD element, or the like, may be used in parallel with any of the foregoing techniques, to provide additional illumination dynamic range.

Table 2 shows various factors which may be used in various combinations to provide a desired illumination level, including the use of a partially-transmitting type of SLM. Row 1 shows that an LCD pixel array may provide a variable illumination attenuation that may be controlled with an 8-bit gray-level command. However, in practice, the actual level of variation observed in the transmitted light is limited to approximately 150:1. Row 2 shows that an LCD pixel array may provide a variable “brightness” attenuation that affects all pixels at once, and may provide an actual level of variation observed in the transmitted light that is approximately 1.2:1. Row 3 shows that a Xe strobe lamp may provide a variable “brightness” depending on its operating voltage level, and may provide an actual level of variation observed in the provided and transmitted light that is approximately 17:1. Row 4 shows that a Xe strobe lamp generally provides an effective exposure time that is shorter than a typical minimum camera integration period, therefore, for strobe exposures, the overall duration of the camera exposure period is not used to affect the exposure. However, as previously indicated, the pulse duration may be set so as to stop the image exposure to effectively truncate part of the flash profile. Row 5 shows that the pulse trigger delay (for example, see [T_(pt)-T_(si)], FIG. 7), which governs the relative timing between the camera integration period and the flash profile, may be adjusted in 40 ns time steps. That is, the flash profile may be selectively eliminated from the image exposure, in 40 ns time steps. In practice, the actual level of variation observed in the transmitted light by using this control measure may be approximately 250:1. Rows 6 and 7 show factors which may vary from machine to machine, lamp to lamp, etc. Generally, it may be desirable to calibrate and/or compensate these variations. Overall, according to Table 2, all of these techniques may be used in combination to provide an effective image exposure illumination dynamic range of approximately 765,000:1 in a set of relatively precisely controlled and repeatable increments. TABLE 2 Actual Adjustment Adjustment effect on Item Setting steps Units exposure Control Level 1 Pixel  0-255 DN 150:1 Individual light brightness (8 bit) channels (Individual (SLM) Pixels of SLM) 2 Display 0x00-0x80 DN  1.2:1 All Light Channels brightness together (SLM) (Entire SLM at once) 3 Xe brightness 150-600 Volts Volt  17:1 All Light Channels (flash lamp) together 4 CCD exposure  0.1-250 10's of μs time None All Light Channels (Tei-Tsi) (but stable together (Entire and camera at once) Note: repeatable) No effect for strobe exposures. Strobe pulse timing controls effective exposure time. 5 Pulse trigger  0-250 40 ns time time 250:1* All Light Channels delay steps together (Tpt-Tsi) 6 Pulse rise time f(V_(FL)) None. Fixed time None Pulse delay vs. lamp delay or calibrated voltage is (Tpt-Tsp) characterized. Used to compensate Tpt, if needed. 7 Xe pulse 10-30 None. Fixed μs None or calibrated

FIG. 10 is a plot 1000 illustrating exemplary generic relationships between a light setting (power setting) during a continuous illumination that may be satisfactory during a reference or standard exposure time, and corresponding respective strobe duration times for a number of respective strobe light power levels represented by lines 1010, 1020, 1030. When using the light generation system 300 or 300′ and the various systems and methods outlined above, particular strobe duration times may be implemented by controlling the various timing relationships outlined above with reference to FIGS. 7 and 8.

The abscissa in FIG. 10 may correspond to the light setting (power setting) during continuous illumination that produces a satisfactory “stationary” workpiece image that may be acquired throughout a reference or standard exposure time, such as the frame rate of conventional cameras. This method of illumination and exposure may be conventional, and may be well-suited for operation of a vision machine during manual operations and training mode operations that involve a machine operator. The ordinate in FIG. 10 may correspond to a strobe duration time necessary for a given strobe light power to achieve an image intensity equivalent to the light setting (power setting) during continuous illumination, that is, to achieve the same total exposure illumination energy for that light source.

A particular total exposure illumination energy may be defined as corresponding to a particular continuous illumination level, when using the reference or standard exposure time. This energy may be divided by a particular strobe light average power level that may directly determine the corresponding required strobe duration time to a first approximation. Each of the exemplary strobe light power curves 1010, 1020, 1030 may reflect a respective strobe lamp power setting consistent for each point along the respective curves. Thus, operation according to any point along the higher power curve 1030 may allow a shorter strobe duration time than operation according to corresponding (vertically aligned) points along either of the lower power curves 1020, 1010. When using the light generation system 300 or 300′ and the various systems and methods outlined above, higher strobe light power curves may correspond to higher strobe lamp operating voltages and/or controlling the pixels of an LCD pixel array used for the SLM 350 to be fully transmitting. Lower strobe light power curves may correspond to lower strobe lamp operating voltages and/or controlling the pixels of an LCD pixel array used for the SLM 350 to be only partially transmitting.

In order to provide the shortest possible strobe duration and produce images having the least motion-related blur and the smallest possible uncertainty in the elevation distance, there are advantages to operating at a point toward the lower left end of any strobe light power curve.

Each strobe light source may inherently have a maximum allowable power level and, in the absence of other camera response considerations, and other analogous devices, this factor may determine the fastest allowed strobe duration. The higher power curve 1030 generally represents such a maximum power level. For a maximum or selected power level and a desired operating point, for example, as indicated by the line 1040, the corresponding strobe duration period may then be determined.

The strobe duration period may provide the required matching total exposure illumination energy. The lines 1050, 1060, generally represent alternative settings for providing a desired illumination level by using respective strobe duration times corresponding to respective strobe light power levels. Also, for a desired strobe duration time defined along the ordinate, the corresponding required strobe light power may be determined at the intersection of the abscissa and ordinate values in the plot 1000.

An operator may input control parameters such as workpiece positions, light source intensity mixtures, etc. to inspect one or more workpieces manually, semi-automatically, or automatically. An example of types of parameters that may be entered is shown in Table 3 below. Parameters such as workpiece image acquisition positions, stage velocity, magnification, light intensities, etc., may be provided. TABLE 3 Parameter Name Parameter Value 1 Workpiece Position(s) X-, Y-, Z-coordinates 2 Stage Velocity V 3 Ring light: % of available power 100% or duty cycle 4 Coaxial light % of available power 75% or duty cycle 5 Stage Light % of available power 50% or duty cycle 6 Magnification 1 x 7 Edge Position Tolerance or ±1.5 micron or ±0.25 pixels Allowable Blur 8 etc. etc.

The parameters in Table 3 are only examples, and in particular situations, more, or fewer, or alternate parameters may be necessary for compatibility with different equipment designs.

The control parameters may be determined by an operator who places a sample workpiece 20 (FIG. 2) onto the stage 210 (FIG. 2) and determines the best position, magnification, lighting, etc., with which to perform the image capture to obtain optimal results. An operator may image a sample workpiece 20 with various parameter combinations and observe the image captured by the camera 260 (FIG. 2) and assess whether the edges are properly determined. After obtaining an operable set of parameters, the operator may enter those parameter values as programmed control parameters.

The control system portion 120 may process the control parameters established by the operator that may be obtained during the static imaging conditions of a training mode and convert them to appropriate control commands for dynamic image capture during the continuous motion conditions of an automatic inspection mode. For example, successive image acquisition locations and the associated total illumination energy to be provided by each light source may be established by the operator during a training mode and the measurement path, velocities, SLM settings corresponding to the various light sources, effective strobe duration period corresponding to the various light sources, etc, may then be optimized by appropriate processing and/or analysis in the control system portion 120 (FIG. 2), in order to yield the highest throughput, or best accuracy, etc., during automatic inspection program execution. After the dynamic image capture control commands for the automatic inspection program have been generated, the control commands (and the control parameters) may be stored in the memory 140 for later retrieval and use.

After processing the control parameters and/or retrieving control commands from the memory 140 (FIG. 2), the control system portion 120 downloads image acquisition position parameters, the associated light control command information, and any other appropriate information to the lighting control interface 133 and/or the light channel exposure and control portion 135 and/or the light generation system 300 and may control the other system components to execute an inspection process. In various applications, it may be desirable to use the dedicated processing and deterministic timing of the light generation system 300 in order to simultaneously control the high speed light pulse patterns of multiple light sources with sufficient accuracy, and at the desired position along a high-speed motion path. For example, the motion controller 132 may receive stage velocity information and command the stage 210 to move the workpiece 20 after receiving position information from the light generation system 300, which may receive control commands from control system portion 120 and processes the control commands into specific data to control an image capture operation.

The captured images may be processed by the video tool portion 143. The image capture cycles may be repeated until completion of a total number of inspection images for each workpiece 20 (FIG. 1), and the control system portion 120 issues a next position signal corresponding to a next (if any) workpiece 20.

FIG. 11 is a flowchart illustrating an exemplary method 1100 of using an a strobe light source and a spatial light modulator to provide desired illumination levels for one or more light sources in a machine vision inspection system. The operations shown in FIG. 11 may be executed, for example, during learn mode operations of the machine vision inspection system 10′, in order to determine various light control parameters that may to be used to provide strobe illumination during run mode operations. The method may begin in step S1105 and proceed to step S1110, wherein the light channel apertures of a controllable SLM may be set to correspond to one of more light sources selected by a user to illuminate a workpiece feature to be inspected. For example, for light sources not selected by a user, the SLM may be controlled to set the corresponding light channel apertures to an “OFF” condition. The selected light channel apertures may be tentatively set to an “ON” condition. The method may then proceed to step S1120, wherein machine vision inspection system inputs the light power or intensity settings that are associated with the various selected light sources. The light power or intensity settings may be determined manually by a user, based on observation of real time images while the user adjusts the light sources during the learn mode operations, or automatically, based on methods taught in U.S. Pat. No. 6,627,863, which is incorporated herein by reference in its entirety. In some implementations, a light power setting of zero may indicate an “OFF” setting for a light source, and steps S1110 and S1120 may be merged or indistinguishable.

In step S130, the machine vision inspection system may analyze the light power or intensity settings input in step S1120 and determine timing relationships between the strobe flash profile and the camera integration period, and/or a strobe lamp operating voltage, based on the light power or intensity settings, such that the strobe illumination that is integrated during the camera integration period provides an illumination level that is sufficient for all of the respective selected light source channels, in comparison to their respective light power or intensity settings. The control parameters corresponding to the determined timing and/or voltage level may be stored in memory and/or implemented in the appropriate circuits or routines. The corresponding strobe illumination level may exceed the respective light power or intensity settings for some or all of the light source channels, if a controllable SLM is available to attenuate the light transmission to the various light source channels. In a decision step S1140, it may be determined whether the timing and/or voltage level determined in step S1130 is sufficient to provide the desired light power and/or intensity setting for each selected light source. If so, then operation mayjump to step S1160. Otherwise, operation proceeds to step S1150. In step S1150, the respective light channel apertures are adjusted in the SLM to provide respective partial light transmission settings and/or respective aperture sizes that provide a level of light transmission attenuation that provides the desired light power and/or intensity level for each respective light channel. It should be appreciated that a light channel aperture size can be reduced in the SLM, instead of, or in addition to adjusting the pixel gray-levels or the like, in order to attenuate the light transmission through a light source channel aperture. It should be appreciated that in the step S1150, the SLM may be adjusted independently for each light source channel aperture, such that one strobe flash can be differently attenuated for each respective light source channel, to provide a desired combination of illumination levels for multiple light sources during a single flash.

In an optional step S1160, the light control settings determined in steps S1130-S1150 may be tested by acquiring and evaluating a workpiece image using the settings. For example, the user may observe the resulting image on a display of the machine vision inspection system during learn mode, and accept or reject the image. If the image is rejected, the light control settings may be refined and retested until an acceptable image results. However, if the image illumination is not critical for a particular image, and/or if the various light control settings are adequately accurate and/or calibrated such that reliable illumination levels are obtained without confirmation of the determined settings, then the step S1160 may be omitted. In step S1170 the final light control settings determined in steps S1130-S1160 may be applied to acquire a workpiece image suitable for learn mode inspection operations and/or recorded, for example, in a part program that may be used later for automatic high-speed inspection. The process may then end in step S1175.

Artisans having skill in the art will recognize and understand that various functions for the systems and methods for controlling strobe illumination may be performed in any manner among any quantity (e.g., one or many) of hardware and/or software modules or units, computers or processing systems or circuitry. The control system portions may be integrated within a stand-alone system or may be executed separately and be coupled to any number of devices, workstation computers, server computers or data storage devices via any communications medium (e.g., network, modem, direct connection, wireless transmission).

The control system processes may be implemented by any quantity of devices or processing systems (e.g., IBM-compatible, Apple, Palm Pilot, Blackberry). The computer system may include any commercially available or customized operating system (e.g., Windows, Macintosh, Unix, Linux, OS/2, DOS) to execute any commercially available or custom designed software (e.g., Quick Vision™) and any type of input devices (e.g., keyboard, mouse, microphone, I/O port, wireless receiver). It is to be understood that the software of the strobe illumination control may be implemented in any desired computer language (e.g., C, C++, Java, Fortran, Lisp, SQL), and could be developed by one of ordinary skill in the computer and/or programming arts based on the functional description contained herein. Moreover, such software may be available or distributed via any suitable medium (e.g., stored on magnetic or optical devices such as CD-ROM and diskette), downloaded from the internet or other network (via packets and/or carrier signals), downloaded from a bulletin board (via carrier signals), or other conventional distribution mechanisms.

It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also, various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, and are also intended to be encompassed by the following claims. 

1. A system for controlling image exposure strobe illumination provided by a plurality of respective light channels in a machine vision system, comprising: a camera; a strobe illumination source that emits radiation usable by the camera for imaging; a controllable spatial light modulator that provides a plurality of controllable respective light channel apertures positioned to receive the emitted radiation; a control system portion that controls the spatial light modulator; and a plurality of respective light cables corresponding to the plurality of respective lighting channels, the respective light cables positioned to receive radiation transmitted from respective light channel apertures, wherein the spatial light modulator is controlled to determine which of the plurality of controllable respective light channel apertures transmits the emitted radiation to their corresponding respective light cable.
 2. The system according to claim 1, comprising at least one respective structured light channel, wherein the controllable spatial light modulator is controlled to provide a structured light pattern positioned to receive the emitted radiation and transmit the emitted radiation in the form of a corresponding structured light to the at least one structured light channel.
 3. The system according to claim 1, wherein the spatial light modulator is further controlled to determine respective attenuations provided by the respective light channel apertures before transmitting the emitted radiation to their corresponding respective light cables thereby further controlling the image exposure strobe illumination.
 4. The system according to claim 3, wherein the respective attenuations are determined by at least one of gray-level control of the respective light channel apertures and size control of the respective light channel apertures.
 5. The system according to claim 3, wherein the control system portion further controls at least one timing relationship between an image integration period of the camera and a timing of a pulse profile of the radiation emitted by the strobe illumination source to further control the image exposure strobe illumination.
 6. The system according to claim 5, wherein the timing relationship causes the image integration period to end during the pulse profile of the radiation emitted by the strobe illumination source, such that a remaining portion of the pulse profile does not affect the image exposure.
 7. The system according to claim 3, wherein the control system portion further controls an operating voltage of the strobe illumination source to further control the image exposure strobe illumination.
 8. The system according to claim 1, wherein the spatial light modulator comprises an LCD pixel array.
 9. The system according to claim 1, wherein the strobe illumination source comprises a Xenon flash lamp.
 10. The system according to claim 1, wherein a location of at least some of the plurality of controllable respective light channel apertures is adjusted using software parameters, such that the at least some of the plurality of controllable respective light channel apertures are aligned to a desired degree with corresponding respective light cables.
 11. A method for controlling image exposure strobe illumination provided by a plurality of respective light channels in a machine vision system, comprising: emitting radiation from a strobe illumination source, the radiation usable for imaging by a camera of the machine vision system; and operating a control system portion of the machine vision inspection system to control a spatial light modulator that provides a plurality of controllable respective light channel apertures positioned to receive the emitted radiation, wherein: the machine vision system comprises a plurality of respective light cables corresponding to the plurality of respective lighting channels; the respective light cables are positioned to receive radiation transmitted from respective light channel apertures, and the step of operating the control system portion of the machine vision inspection system to control the spatial light modulator comprises determining which of the plurality of controllable respective light channel apertures transmits the emitted radiation to their corresponding respective light cable.
 12. The method according to claim 11, wherein the machine vision system comprises at least one respective structured light channel, and the method further comprises operating the control system portion of the machine vision inspection system to control the spatial light modulator to provide a structured light pattern positioned to receive the emitted radiation and transmit the emitted radiation in the form of a corresponding structured light to the at least one structured light channel.
 13. The method according to claim 11, wherein the step of operating the control system portion of the machine vision inspection system to control the spatial light modulator further comprises controlling the spatial light modulator to determine respective attenuations provided by the respective light channel apertures before transmitting the emitted radiation to their corresponding respective light cables thereby further controlling the image exposure strobe illumination.
 14. The method according to claim 13, wherein the respective attenuations are determined by controlling at least one of a gray-level of the respective light channel apertures and a size of the respective light channel apertures.
 15. The method according to claim 13, further comprising operating the control system portion of the machine vision inspection system to control at least one timing relationship between an image integration period of the camera and a timing of a pulse profile of the radiation emitted by the strobe illumination source to further control the image exposure strobe illumination.
 16. The method according to claim 15, wherein the timing relationship is controlled to cause the image integration period to end during the pulse profile of the radiation emitted by the strobe illumination source, such that a remaining portion of the pulse profile does not affect the image exposure.
 17. The method according to claim 13, furter comprising operating the control system portion of the machine vision inspection system to control an operating voltage of the strobe illumination source to further control the image exposure strobe illumination.
 18. The method according to claim 11, wherein the spatial light modulator comprises an LCD pixel array.
 19. The method according to claim 11, wherein the strobe illumination source comprises a Xenon flash lamp.
 20. The method according to claim 11, further comprising operating the control system portion of the machine vision inspection system to adjust a location of at least some of the plurality of controllable respective light channel apertures using software parameters, such that the at least some of the plurality of controllable respective light channel apertures are aligned to a desired degree with corresponding respective light cables. 